Apparatus for bagging a bale and method of bagging such bale

ABSTRACT

A bale bagging apparatus and method are provided. The bale bagging apparatus includes a bale feeding station, a bale chute, a bale bagging station, and a transportation system that transports a bale to be bagged from the bale feeding station through the bale chute and into the bale bagging station. The bale bagging station includes a bag receptacle, a first opening, and a bag retrieval assembly. The bag receptacle is positioned on a side opposite of the first opening from the side of the first opening on which the bale to be bagged is to be transported. The bag retrieval assembly retrieves a bag from the bag receptacle through the first opening. The bag retrieval assembly positions a first end of said bag around at least a portion of the bale chute before the bale to be bagged is transported through the bale chute by the transportation system.

CROSS REFERENCE

This application claims the benefit of U.S. provisional application No.62/139,605, filed Mar. 27, 2015, which is incorporated herein in itsentirety.

FIELD

The present disclosure relates to an apparatus for bagging a bale offibrous material and method of bagging such bale.

SUMMARY

The present disclosure describes a bale bagging apparatus that includesa bale feeding station, a bale bagging station, and a sealing module,provided in that order along an axis of the bale bagging apparatus. Thebale bagging apparatus further comprises a bale pusher assemblyconfigured to push a bale to be bagged through the bale feeding station,the bale bagging station, and the sealing module. The bale baggingstation includes a bale chute through which the bale to be bagged ispushed, a bag receptacle provided below a bale-bag gate, the bale-baggate being configured to support the bale to be bagged when the bale tobe bagged is pushed over the bale-bag gate, while the bale-bag gate isopening when not supporting a bale to be bagged to allow a bag retrievalassembly to retrieve a bag from the bag receptacle.

The present disclosure also describes an embodiment of a baggingapparatus for bales of compressed material, such as cotton, having abase frame parallel to a longitudinal feed direction, a conveyor systemcoupled to the base frame, a bale feeding station at one end of the baseframe member, a bale chute coupled to the base frame downstream of thebale feeding station along the longitudinal feed direction, a baggingstation coupled to the base frame member between the first and secondends after the bale chute, a gantry having a gantry beam coupled to topsections of vertical supports parallel the longitudinal feed directionbetween the first and second ends of the base frame member, a balepusher having a driving mechanism coupled to the base frame arranged tomove in the longitudinal feed direction, and a sealing module located atthe second end of the base frame member and a method for baggingthereof.

The resulting bale bagging apparatus has a simple construction for easyinstallation that allows the efficient and easy placement of a bagaround the bag chute for bagging a bale.

In accordance with the structure of the described embodiment, thebagging station is located downstream of the bale chute along thelongitudinal feed direction between the first and second ends of thebase frame member. The bagging station has a gantry and the secondsection and gap section of the conveyor system, where the at least onegap section is provided between second and third sections of theconveyor system in the bagging station. The gantry has at least twovertical supports having top sections, a gantry beam having ends coupledto the top sections of the two vertical supports, a track coupled to thegantry beam, and a retrieval device movably coupled to the gantry beam.The vertical supports are positioned transversely from the base framemember so that the gantry and retrieval assembly is positionable alongthe longitudinal feed direction and second gap section.

The retrieval assembly is configured to pick-up an open end of the bagfrom a pallet of bags so that a closed end of the bag hangs downwardly.The retrieval device can then move from a first position to a secondposition, where the second position is a position where the closed endof the bag is aligned perpendicularly to the longitudinal feed directionto the at least one gap section. After which, the retrieval device movesin a direction transverse to the longitudinal feed direction so that theclosed end of the bag is positioned in the at least one gap section. Theopen end of the bag can then be moved in the longitudinal directionforwardly towards the bag chute to position the open end of the bagaround the bale chute.

This inventive structure allows the straightening of the bag forplacement of the bag around the bale chute in a compact, efficientarrangement. By straightening the length of the bag, the bag is betterpositioned to receive the bale fed into the bale chute using a simpleand easy to install structure.

Additionally, the second section of the conveyor system can compriserollers inclined outwardly and upwardly from a center position of thesecond section. By inclining the rollers, the bagged bale fed from thebale chute only contacts the rollers of the second section of theconveyor system along corners of the bale. Since the corners of the baleare mostly cotton and the bottom surface of the bale does not directlycontact the rollers, damage to the bag from the bailing wire or otherhard surfaces is mitigated. Additionally, there is lower frictionalresistance for bagging the bale.

According to another embodiment, a bale bagging apparatus is provided.The bale bagging apparatus includes a bale feeding station, a balechute, a bale bagging station, and a transportation system thattransports a bale to be bagged from the bale feeding station through thebale chute and into the bale bagging station. The bale bagging stationincludes a bag receptacle, a first opening, and a bag retrievalassembly. The first opening is defined by a first rail and a secondrail. The bag receptacle is positioned on a side opposite of the firstopening from the side of the first opening on which the bale to bebagged is to be transported. The bag retrieval assembly retrieves a bagfrom the bag receptacle through the first opening. The bag retrievalassembly positions a first end of said bag around at least a portion ofthe bale chute before the bale to be bagged is transported through thebale chute by the transportation system.

According to another embodiment, a method of bagging a bale is provided.A bale to be bagged is received at a feeding station. A bag is retrievedfrom a bag receptacle through a first opening. The first opening isdefined by a first rail and a second rail. The bag receptacle ispositioned on a side opposite of the first opening from the side of thefirst opening on which the bale to be bagged is to be transported. Afirst end of the bag is positioned around at least a portion of saidchute. The bale to be bagged is transported through said bale chute andis thereby placed within said bag.

The numerous advantages, features and functions of the variousembodiments of the disclosure will become readily apparent and betterunderstood in view of the following description and accompanyingdrawings. The following description is not intended to limit the scopeof the apparatus for bagging a cotton bale, but instead merely providesexemplary embodiments for ease of understanding. Although a cotton baleis described in some of the embodiments described herein, bales orbundles or any finished or unfinished material may be bound and baggedaccording to the various examples and embodiments described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples of a cotton bale bagging apparatus according to differentembodiments of the disclosure will now be explained in more detail withreference to the drawings, wherein:

FIG. 1 shows a right side view of a bale bagging apparatus according toan embodiment showing a bale feeding station, a bale pusher, a balechute, a gantry, a bale bagging station, a sealing module, and aconveyor system for transporting a bale along the bale bagging apparatusalong a longitudinal feed direction;

FIG. 2 is a top side view of the bale bagging apparatus of an embodimentshowing the tops of each section of the bale bagging apparatus;

FIG. 3 is a right side isometric view of the bale bagging apparatusaccording to an embodiment showing the sections of the bale baggingapparatus;

FIG. 4 is a longitudinal front view of the bale bagging apparatusaccording to an embodiment showing the bale feeding station and the balefeeder towards the bale chute;

FIG. 5 is a right side isometric view of the bale chute illustratedaccording to the embodiments in FIGS. 1-3 showing a closed position ofat least four pivotable sections;

FIG. 6 is a right side isometric view of the bale chute illustratedaccording to the embodiments in FIGS. 1-3 showing an intermediary openposition of the at least four pivotable sections;

FIG. 7 is a right side isometric view of the bale chute illustrated inFIGS. 1-3 showing an open position of the at least four pivotablesections;

FIG. 8 is a longitudinal back view of a bagging station and bale chuteof a second embodiment of a bale bagging apparatus having inclinedrollers;

FIG. 9 is a right side isometric view of a bale bagging apparatusshowing an embodiment of a method for placing a bag around pivotingsections of an output end of the bale chute by picking up a bag from abag pallet;

FIG. 10 is a right side view of the bale bagging apparatus according toFIG. 9 showing the picking up of the bag by the retrieval assembly sothat the open end of the bag opens and the closed end hangs downwardly;

FIG. 11 shows moving the bag retrieval assembly according to anembodiment so that the closed end of the bag moves through the at leastone gap section of the bagging station;

FIG. 12 illustrates moving the open end of the bag towards the balechute so that the closed end of the bag is straightened;

FIG. 13 shows the pivoting sections of the bale chute opening accordingto an embodiment to engage the open end of the bag;

FIG. 14 illustrates the feeding of a bale from the bale feeder to thebale feeding station for feeding the bale to the bale bagging apparatusalong the conveyor system;

FIG. 15 shows pushing the bale down the bale bagging apparatus accordingto an embodiment from the bale feeding station to the bale chute alongthe longitudinal feed direction using the bale pusher;

FIG. 16 depicts the bale pusher according to an embodiment continuingpushing the bale into the open end of the bag through the bale chuteonto the second section of the conveyor system;

FIG. 17 illustrates the release of the open end of the bag according toan embodiment by the pivoting sections of the bale chute as the balepusher continues pushing the bagged bale down the bale bagging apparatusin the longitudinal feed direction;

FIG. 18 shows the bale pusher reaching a second position according to anembodiment where the bagged bale is placed on a sealing module at thesecond end of the bottom frame member;

FIG. 19 illustrates the closing of the open end of the bag around thebale according to an embodiment at the sealing module by first havingright and left closing actuators close the right and left flaps of theopen end of the bag;

FIG. 20 shows the closing of a top flap of the open end of the bagaround the bale according to an embodiment after the right and leftflaps are closed;

FIG. 21 depicts the closing of a bottom flap of the open end of the bagaccording to an embodiment after the top, right, and left flaps areclosed;

FIG. 22 illustrates a sealing element according to an embodiment used atthe sealing module for sealing the open end of the bag;

FIG. 23 illustrates an alternative embodiment wherein a sealing elementis used to close and seal the open end of the bag; and

FIG. 24 illustrates an alternative feeding device at the bale feedingstation.

FIGS. 25A and 25B illustrate right perspective view and a leftperspective view, respectively, of a bale bagging apparatus according toan alternative embodiment.

FIGS. 26A and 26B show a front view and a back view, respectively, ofthe bale bagging apparatus according to the embodiment of FIGS. 25A and25B.

FIGS. 27A and 27B show a right view and a left view, respectively, ofthe bale bagging apparatus according to the embodiment of FIGS. 25A and25B.

FIG. 28 shows a right perspective view of the load unit and the bag unitaccording to an embodiment.

FIG. 29 shows a right perspective view of a staging device according toanother embodiment.

FIG. 30 shows a right perspective view of a pusher assembly of anembodiment.

FIGS. 31A and 31B illustrate a right perspective view and a leftperspective view, respectively, of the pusher track assembly accordingto the embodiment of FIG. 30.

FIG. 32 shows a view of the pusher head assembly according to theembodiment of FIG. 30.

FIG. 33 shows a right perspective view of the gantry assembly accordingto an embodiment.

FIG. 34 shows a right perspective view of the gantry trolly assemblyaccording to the embodiment of FIG. 33.

FIG. 35 illustrates a gantry arm assembly according to the embodiment ofFIG. 33.

FIG. 36 illustrates a chute assembly according to an embodiment.

FIG. 37 shows a bag/bale gate assembly according to an embodiment.

FIG. 38 illustrates a bag drawer assembly according to an embodiment.

FIG. 39 shows a left-side sample assembly according to anotherembodiment.

FIG. 40 illustrates a right-side sample assembly according to anembodiment.

FIG. 41 shows a right perspective view of a closer assembly according toan embodiment.

FIG. 42 shows a right perspective view of weigh and drop unit accordingto an embodiment.

FIG. 43 illustrates a perspective view of a weigh table assemblyaccording to the embodiment of FIG. 42.

FIG. 44 illustrates a perspective view of a bale drop unit assemblyaccording to the embodiment of FIG. 42.

FIG. 45 illustrates a right-rear perspective view of a bale push unitaccording to an embodiment.

In the various figures, similar elements are provided with similarreference numbers. It should be noted that the drawing figures are notnecessarily drawn to any scale, or proportion, but instead are drawn toprovide an understanding of the method according to the disclosure andthe resulting piston form and components. Thus, the illustrations arenot intended to be limiting as to the scope of the disclosure describedherein, but rather to provide exemplary illustrations thereof.

DETAILED DESCRIPTION A. Discussion of Various First Embodiments

As generally discussed above, known bale bagging systems havecomplicated designs involving multiple separate modules and stepsincluding various moving mechanical parts and complex structures thatrequire careful maintenance and that are prone to malfunction.Mechanical systems and modules of known bagging systems are often openand thus more dangerous to operate and due to the various separate andisolated modules of the process have a large physical footprint in acotton bale processing plant. To overcome this shortcoming, theembodiments in the present disclosure were developed to create an easyto install cotton bale bagging machine that is simpler to manufactureefficiently and commercially practical. The bale bagging systemdescribed herein is also much safer and compact, having a much smallerfootprint.

For example, as seen in FIG. 1, one embodiment of the cotton balebagging machine 100 includes a bale feeding station 300 on a first endof the cotton bale bagging machine 100, a sealing module 800 on a secondend of the cotton bale bagging machine 100, a bale chute 500, a gantry700, and a bale bagging station 600 between the first and

second ends of the bale bagging machine 100, and a conveyor system 200that is coupled to the bale feeding station 300, sealing module 800, andbale bagging station 600 in a way such that the conveyor system 200 isused to transfer a bale, e.g., cotton bale, in a longitudinal and linearfeed direction from the bale feeding station 300 to the sealing module800.

The cotton bale bagging machine 100 also has a base and a bottom framemember 105 at the base of the bale bagging machine 100 that runssubstantially linearly in the longitudinal direction to support the balefeeding station 300, the bale chute 500, the sealing module 800 and theconveyor system 200. One end of the bottom frame member 105 ispositioned near the bale feeding station 300, while the second end ispositioned near either the sealing module 800 or near the bale baggingstation 600. When the second end of the bottom frame member 105 ispositioned near the bale bagging station 600, the bottom frame member105 further comprises a second section for supporting the sealing module800.

The bottom frame member 105 has a solid or hollow beam and/or at leasttwo linear bars or beams to create a frame that has the linear bars orbeams positioned parallel to the longitudinal feed direction andconnected transversely by feet for supporting the base. The bottom framemember 105 is made from steel, ferrous alloys, composite materials, orother material that can be used to support the stations and bale duringthe bale bagging operation.

Additionally, the bale bagging machine 100 has at least two verticalsupports 110 for supporting the gantry 700 between the first and secondends of the bale bagging machine 100. Preferably, four vertical supports110 are used for supporting the gantry 700, so that the gantry 700 ismovable in longitudinal, transverse, and vertical directions withrespect to the longitudinal feed direction. The four vertical supports110 are positioned transversely on outer sides of the bottom base frame105, where one end of each of the supports 110 is located near the baseof the bale bagging machine 100 and the second end of the support 110 islocated above the conveyor system 200.

This efficient design for a bale bagging machine 100 uses a conveyorsystem 200 comprising at least a first section 205, a second section210, a third section 215, and a gap section 220. The first section 205of the conveyor system 200 is located at the first end of the balebagging machine 100 near the bale feeding station 300, while the secondsection 210 is located at the bale bagging station 600 after the balechute 500, and the third section 215 is located near the sealing module800 at the second end of the bale bagging machine 100. The gap section220 is located between the second section 210 and the third section 215and has a gap distance greater than the thickness of a bag used forbagging the bale, e.g., a gap distance greater than at least 6 inches.

The conveyor system 200 uses conventional conveyors known in the art.For example, rollers are used which are rotatably coupled to a frame ortray. The rotating rollers can then be used as a guiding mechanism tohelp move the bale in the desired directions by having the rollersrotate in the transverse and longitudinal directions. The rotatingrollers can be made from Teflon, plastic, metal, or other material thatfacilitates the movement of the bale along the bale bagging machine 100.Additionally, the conveyor system 200 can also use belts, chains, and/orother driving mechanisms to move the bale in the longitudinal andtransverse directions.

The embodiment of the bale bagging machine 100 as seen in FIGS. 1-5 willbe described in greater detail below.

As further seen in FIGS. 1-4, the bale feeding station 300 includes abale receiver 305, a staging device 310 located at the first end of thebale bagging machine 100, and the first section 205 of the conveyorsystem 200. The bale feeding station 300 is coupled to the first end ofthe bottom frame member 105 along vertical beams coupled to the bottomframe member 105.

The bale receiver 305 is an opening along the first section 205 that isused to receive a bale from a bale feeder 315 connected to the first endof the bottom frame member 105. The bale feeder 315 uses an inclineddrag chain conveyor, guided or non-guided motorized or actuated transfercart, carriages, slides, or other device to move the bale from a flooror input bale feed to the bale receiver 305. The bale feeder 315 may becoupled to the bale feeding station 300 or to the bottom frame member105 to allow the feeding of the bale in a transverse direction withrespect to the longitudinal feed direction or in the same direction asthe longitudinal feed direction.

The first section 205 uses transverse rotating rollers 206 coupled to aframe using pins or other fastening devices to allow the rollers torotate in a transverse direction with respect to the longitudinal feeddirection. By having the transverse rotating rollers 206 rotate in thetransverse direction, the bale fed through the bale receiver 305 cancontinue to move transversely onto the first section 205 of the conveyorsystem 200 for the simple staging of the bale.

FIG. 2 shows that a first gap 207 can be provided between two or moretransverse rotating rollers 206 of the first section 205. The first gap207 has a gap width that allows a bale pusher 400 to move in thelongitudinal feed direction between the at least two transverse rotatingrollers 206, as discussed below in detail. The transverse rotatingrollers 206 of the first section 205 can be driven to rotate in thetransverse direction using a roller drive (not shown) or can freelyrotate.

The staging device 310 of the bale feeding station 300 is a side bumper311 located on the opposite side of the bale receiver 305 across thefirst section 205 of the conveyor system 200 to stage the bale being fedfrom the bale feeding device 315. For example, the side bumper 311 runslinearly in the longitudinal feed direction, i.e., has one end near thefirst end of the bale bagging machine 100 and has another end closer tothe bale bagging station 600. By having the side bumper 311 located onthe opposite side of the bale receiver 305, the side bumper 311 isarranged to stop the bale fed onto the transverse rotating rollers 206to easily and simply stage the bale in an appropriate position for thelongitudinal feeding of the bale along the bale bagging machine 100.

The staging device 310 can also include a switch or a photoeye or lightcurtain (not shown) to detect the presence of the bale at theappropriate location. When the bale is detected by the switch orphotoeye or light curtain in the appropriate position, the switch orphotoeye or light curtain can be used to control the movement of theroller drive of the first section 206.

As seen in FIG. 1, the bale pusher 400 has a start position near thebale feeding station 300. The bale pusher 400 has a pushing section 405,a pushing section carriage 410, and a driving mechanism 415 for movingthe bale pusher 400 from the bale feeding section 305 to the secondsection 210 of the conveyor system 200 and back to the bale feedingsection 305. The pushing section carriage 410 couples the pushingsection 405 to the driving mechanism 415 to allow the pushing of thebale in the longitudinal feed direction.

The pushing section 405 of the bale pusher 400 has a planar face thatruns transversely to the longitudinal feed direction. The planar facehas a surface contact area that allows the distribution of force on thepushed bale, so that the pushed bale is not damaged. The pushing section405 and pushing section carriage 410 are made from steel, metal alloys,composites, and other material that is designed for moving loads.

The driving mechanism 415 moves the bale pusher 400 along a linear drivetrack 420 coupled to the bottom frame member 105 linearly in thelongitudinal feed direction. The driving mechanism 415 can be driven bya servo gear motor 416 that drives a rack (not shown), i.e., a gear,along a pinion (not shown) on the linear drive track 420. In anotherembodiment, other drive mechanisms could be used to move the drivingmechanism 415 along the linear drive track 420, such as, chains,pulleys, or similar devices.

The bale chute 500 is positioned after the first section 205 but beforethe bale bagging station 600. The bale chute 500 has an input end 505near the bale feeding station 300 and an output end 510 near the balebagging station 600 for receiving and discharging the bale movedlongitudinally along the bale bagging machine 100. The bale chute 500comprises at least two pivoting sections, but preferably, has at leastfour pivoting sections 515, 516, 517, 518, mounted on a chute frame 520attached to the bottom frame member 105.

As seen in FIGS. 5-7, the at least four pivoting sections 515, 516, 517,518 are pivotally connected to the chute frame 520 using actuators 525,e.g., double acting

pneumatic cylinders, to move between at least a closed position and anopen position. The positioning of the actuators 525 are controlled usinga controller (not shown).

FIG. 5 shows the at least four pivoting sections 515, 516, 517, 518pivoted in the closed position, where the actuators 525 pivot thepivoting sections 515, 516, 517, 518 towards each other to a centerposition of the bale chute 500, i.e., the pivoting sections are pivotedtowards the other pivoting sections. As seen in FIG. 7, the at leastfour pivoting sections 515, 516, 517, 518 can also be pivoted from theclosed position to the open position, where the four pivoting sections515, 516, 517, 518 are driven outwardly away from the center position ofthe bale chute 500, i.e., the pivoting sections are pivoted away fromthe other pivoting sections.

FIG. 6 illustrates an intermediary open position that can also be usedwhere the at least four pivoting sections 515, 516, 517, 518 are notfully opened. In this intermediary position, the at least four pivotingsections 515, 516, 517, 518 are pivoted outwardly away from the centralposition of the bale chute 500 to a position where outer sides of thepivoting sections are substantially parallel to each other. From thisposition, at least the top pivoting sections 515, 516 are pivotedfurther away from the center of the bale chute 500, i.e., a more openposition as seen in FIG. 7. In this more open position, the outer sidesof the pivoting sections 515, 516 are no longer parallel with theremaining pivoting sections.

Referring back to FIGS. 1-4, the bagging station 600 is located afterthe bale feeding station 300 and the bale chute 500. The bagging station600 includes the second section 210 and the gap section 220 of theconveyor system 200 and the gantry 700. The design of the baggingstation 600 provides an easy to assemble and uniquely designed machinefor the placing of the bag for bagging the bale that utilizes the gapsection 220 and/or inclined rollers for the positioning and the feedingof the bale in the bag.

The second section 210 has at least two roller frames 212 coupled to andsupported by vertical beams connected to the bottom frame member 105 andat least two sets of longitudinally rotating rollers 211 rotatablycoupled to the roller frames 212. A second gap 213 is located at acenter position 214 between the at least two roller frames 212 that hasa width to allow the movement of the bale pusher 400 between the tworoller frames in the longitudinal feed direction.

The two sets of longitudinally rotating rollers 211 can be substantiallyhorizontal with respect to the base of the bale bagging machine 100.Alternatively, as seen in FIG. 8, the rotating rollers 211 can beinclined where one end of the longitudinally rotating rollers 211 islocated near the center position 214 of the second section 210 and theother end is located at an outward position above the one end, i.e., thelongitudinally rotating rollers 211 have an incline angle greater than5° from an imaginary horizontal plane (dotted lines) at the centerposition 214 of the second section 210 to an outer position of each setof roller frames 212.

FIGS. 1-4 show that the gantry 700 is coupled to top sections of the atleast four vertical supports 110 of the bale bagging machine 100 abovethe conveyor system 200. The gantry 700 comprises at least three servodriven motors 705, 706, 707 that are configured to move the gantry inlongitudinal, transverse, and vertical directions, at least twotransverse beams 710 coupled to top sections of the at least fourvertical supports 110 in the transverse direction, a first track coupledto the at least two transverse beams 710, a gantry beam 715 positionedparallel with respect to the longitudinal feed direction, a second track730 coupled to the gantry beam 715, and a bag retrieval assembly 720.

As seen in FIG. 3, a first servo motor 705 is coupled to the gantry beam715 to move the gantry beam 715 along the first track 725 in thetransverse direction with respect to the longitudinal feed direction,i.e., a Y-direction. Additionally, a second servo motor 706 and the bagretrieval assembly 720 are coupled to the gantry beam 715, so that thesecond servo motor 706 can control the positioning of the bag retrievalassembly 720 along the second track 730 parallel to the longitudinalfeed direction, i.e., the x-direction. According to an embodiment, thefirst and second tracks 725 comprise belts and motors to allow themovement of the gantry beam 715 and the bag retrieval assembly 720 intheir respective directions. Additionally, chains, pulleys, rack andpinion gears, or other devices known in the art can be used with thetracks to allow the movement of the devices.

The bag retrieval assembly 720 comprises the third servo motor 707, aretrieval arm 721, and a bag retaining device 722. The bag retainingdevice 722 is coupled to one end of the retrieval arm 721 closest to theconveyor system 200. The retrieval arm 721 is coupled to the third servomotor 707 in a way such that the third servo motor 707 is used tocontrol the vertical position, i.e., the Z-direction, of the retrievalarm 721 in directions towards and away from the conveyor system 200. Thebag retaining device 722 coupled to one end of the retrieval arm 721 hasdevices, e.g., suction cups, clamps, gripping fingers, that areconfigured to grasp the baling bags for displacing the bags, i.e., pickup, from a bag feed position through the bale bagging station 600 to thebale chute 500. The bag retaining device 722 can also have a bag openingdevice 740 coupled to either the bag retaining device 722 or the suctioncups closest to the open end of the bag for maintaining the bags in theopen position. For example, the device for maintaining the bags in theopen position 740 can use a nozzle to inject air into the open end ofthe bag to inflate the bag and maintain the bag in the open position.

In one embodiment, the third servo motor 707 can use various structuresto move the retrieval arm 721 in the vertical direction. For example,the retrieval arm 721 can be positioned vertically using a rack andpinion gear structure, pulleys, belts, chains, or other devices thatallow the controlled positioning of the retrieval arm.

The sealing module 800 is a sealing module known in the art that can usetape or a heating element (830) to close the open end of the bag arounda bagged bale. The sealing module 800, as shown in FIGS. 1-4, includesthe third section 215 of the conveyor system 200, a left closingactuator 805, a right closing actuator 810, and a bottom closingactuator 815.

The sealing module 800 is located at the second end of the bale baggingmachine 100 after the gap section 220 of the bale bagging station 600.The sealing module 800 in this embodiment is supported by and attachedto the second section of the bottom frame member 105 of the bale baggingmachine 100.

The left, right, and bottom actuators 805, 810, and 815 are actuatorsthat have a closing tool 825 attached on one end of the actuator. Theclosing tool 825 is a closing device designed to collapse the open endof the bag over the end of the bale. For example, the closing tool 825is a plate or finger that pushes open ends of the bag in a givendirection.

The left and right closing actuators 805, 810 are coupled to andsupported by vertical beams attached at one end to the second section ofthe bottom frame member 105. The left and right closing actuators 805,810 have a predetermined length and are coupled to the vertical beams tomove transversely with respect to the longitudinal feed direction sothat the closing tool 825 of each right and left closing actuator 805,810 moves in a transverse direction inwardly and outwardly from a centerof the sealing module 800. In this embodiment, the center of the sealingmodule 800 is an imaginary center of a back face of a bale positioned onthe sealing module 800 closest to the actuators, so that the actuatorscan be used to close the open end of the bag around the bale.

The bottom closing actuator 815 is coupled centrally to the bottom framemember at one end so that the closing tool 825 on the other end of thebottom closing actuator 815 can move vertically upwardly towards thecenter of the sealing module 800 and downwardly away from the center.

In an embodiment, the closing actuators 805, 810, and 815 are controlledby a sealing module controller (not shown) to control the positioningand timing of the closing actuators. Additionally, a sealing element(830) is used to close the open end of the bag. The sealing element is atape dispenser, heating element, or other device that can be used toclose an open end of the bag. The sealing element can be mounted on anyof the actuators to facilitate the closing of the bag.

As seen in FIGS. 1-3, the third section 215 of the conveyor system 200is coupled to and supported by vertical beams connected to the bottomframe member 105 and comprises longitudinally rotating rollers 216coupled to a roller frame 217. Similar to the rollers described above,the longitudinally rotating rollers 216 are rotatably coupled to the

roller frame 217 to allow the rotation of the longitudinally rotatingrollers 216 in the longitudinal direction. The longitudinally rotatingrollers 216 can also be driven by a motor (not shown) or allowed tofreely rotate.

The simple structure of the bale bagging machine 100 provides aconvenient and easy to assemble bale bagging machine that can be easilyinstalled on-site for the bale bagging operation. The stations can bedelivered pre-assembled or assembled on site, while the base frame andvertical supports would be delivered for the simple installation at thesite.

B. Discussion of Various Methods of Operation of the Bale BaggingMachine According to the First Embodiments

The operation of the bale bagging machine 100 will now be described indetail with reference to FIGS. 9-22.

FIGS. 9-13 show the picking up of a bag 905 from a pallet of bale bags900. Various retrieval devices can be used for the movement of the bag,as long as the retrieval device is arranged to position the closed endof the bag in the gap section of the conveyor system. For example, theretrieval device can be mounted on a ceiling above the bale baggingapparatus having a device that can position the retrieval device in thevertical direction and longitudinally along the bale bagging machine.

In this embodiment, the pallet of bale bags 900 as shown is located in aposition that is accessible by the bag retrieval assembly 720, i.e., thearea in the gantry 700 between the at least four vertical supports 110of the bale bagging machine 100. The precise position, however, is notlimited to the aforementioned position, but may be adjusted as desiredwithin the operational area of the gantry.

As seen in FIG. 10, the pallet of bale bags 900 are folded in a way suchthat an open end 910 is folded on top of a closed end 915 of the bag1000. When the bag 900 is lifted, i.e., picked up, by the bag retrievalassembly 720, the open end 910 is openable, while the closed end 915hangs downwardly towards the base of the bale bagging machine 100.

FIG. 11 illustrates the transference of the bag 905 from the pallet ofbags 900 to the bale bagging station 600. After picking up the bag 905,the bag retrieval assembly 720 and bag 905 move in parallel to thelongitudinal feed direction rearwardly in this example towards thesecond end of the bale bagging machine 100 with the closed end 915 ofthe bag 905 hanging downwardly.

When the bag retrieval assembly 720 is positioned perpendicular to thegap section 220 of the conveyor system 200, the bag retrieval assembly720 is moved transversely with respect to the longitudinal feeddirection, i.e., a lateral direction, so that the closed end 915 of thebag 905 moves laterally through the gap section 220, i.e., perpendicularto the longitudinal feed direction.

Once the closed end 915 of the bag 905 is positioned in the gap section220, the gantry 700 moves the bag retrieval assembly 720 in the oppositedirection, forward in this example towards the first end of the balebagging machine 100, of the longitudinal feed direction so that the openend 910 of the bag 905 moves towards the bale chute 500.

As seen in FIG. 12, as the open end 910 of the bag 905 moves towards thebale chute 500, the closed end 915 of the bag 905 is positioned on thelongitudinally rotating rollers 211 of the second section 210 of theconveyor system 200 in the bale bagging station 600.

When the open end 910 of the bag 905 is moved towards the bale chute 500by the gantry 700, the pivoting sections 515, 516, 517, 518 of the balechute 500 are in the closed position. FIG. 13 shows that after the openend 910 of the bag 905 is positioned around the pivoting sections 515,516, 517, 518, the pivoting sections are controlled to pivot to the openposition, so that the pivoting sections engage an inside surface of theopen end 910 of the bag 905 to hold the bag 905 in place, i.e., securelyretain the bag.

Surprisingly, it was found that by allowing the closed end 915 of thebag 905 to move through the gap section 220, the positioning of the bag905 over the pivoting sections of the bale chute 500 and subsequentbagging of the bale was facilitated. This positioning allows the bag tobe easily placed in alignment with the longitudinal feed direction toopen the bag for receiving the bale, which greatly improves the balebagging operation.

At another time or the same time as the transferring and positioning ofthe bag 905 around the pivoting sections of the bale chute 500, a bale1000, e.g., a cotton bale, is fed onto the bale feeder 315 for feedingthe bale 1000 into the bale feeding station 300.

FIG. 14 illustrates the movement of the bale 1000, where the dotted linerepresent a first position of the bale 1000 and the solid linerepresents the second position of the bale 1000 fed by an inclined balefeeder 315 towards the bale feeding section 300. As the bale feeder 315is feeding the bale 1000 through the bale receiver 305 of the balefeeding station 300, the transverse rotating rollers 206 of the firstsection 205 can be controlled to rotate transversely with respect to thelongitudinal feed direction.

By rotating the transverse rotating rollers 206 transversely withrespect to the longitudinal feed direction, the bale 1000 is staged onthe first section 205 of the conveyor for the subsequent bagging of thebale 1000 by the bale bagging machine 100. As discussed above, thetransverse rotating rollers 206 are used to stage the bale 1000 by usinga switch or photoeye that starts and stops the transverse rotatingrollers 206 when the desired position of the bale 1000 is detectedand/or rotate until the bale 1000 reaches the side bumper 311.

As seen in FIG. 15, after the bale 1000 is staged on the first section205, the bale pusher 400 pushes the bale 1000 along the longitudinalfeed direction towards the input end 505 of the bale chute 500 bycontrolling the driving mechanism 415 to move along linear drive track420. As discussed above, the first gap 207 is provided to allow the balepusher 400 to move along a linearly positioned central line of the balebagging machine 100 through the first section 205.

The bale pusher 400 pushes the bale 1000 to a first position where oneend of the bale 1000 is positioned near the input end of the bale chute500. The bale pusher 400 then pushes the bale 1000 through the input end505 of the bale chute 500 with the pivoting sections 515, 516, 517, 518on the output end 510 in the open position. When the bale chute 500 isin the open position, another gap is provided along the linearlypositioned central line between at least the bottom pivoting sections toallow the bale pusher 400 to continue moving in the longitudinal feeddirection towards the second end of the bale bagging machine 100.

The bale pusher 400 continues to move in the longitudinal feed directionto push the bale 1000 through the bale chute 500 into the open end 910of the bag 905 so that the bale 1000 engages the longitudinally rotatingrollers 211 of the second section 210. Since the longitudinally rotatingrollers 211 are inclined, the bale 1000 only engages the second section210 at bottom corners of the bale 1000 thereby decreasing any frictionand resistance from placing the bale 1000 into the bag 905. It was alsofound that by inclining the second section 210, the rollers of thesecond section do not significantly engage baling wire that binds thebale 1000, which prevents roller damage and wear.

FIG. 16 shows the bale pusher 400 pushing the bale 1000 towards thesecond end of the bale bagging machine 100 so that the bale 1000 engagesthe closed end 915 of the bag 905. After the bale reaches the closed end915, the bale pusher 400 continues pushing the bagged bale 1000 onto thesecond section 210 of the conveyor system 200. When the bale pusher 400reaches a predetermined position, the pivoting sections 515, 516, 517,518 are closed or set in the intermediary open position to allow the bag905 to be released from the bale chute 500.

As seen in FIGS. 17-18, the bale pusher 400 continues moving the bale1000 in the longitudinal feed direction from the second section 210 ontothe third section 215 in the sealing module 800 until the bale pusher400 reaches a predetermined position. After which, the bale pusher 400returns back to the bale feeding station 300, i.e., reverses directionto move in the opposite direction of the longitudinal feed direction.The travel of the bale pusher 400 can be controlled using a switch,time, or based on a predetermined length of travel.

FIG. 18 shows the bagged bale 1000 pushed on the third section 215 onthe sealing module 800. The longitudinally rotating rollers 215 of thethird section 215 facilitate the movement of the bagged bale 1000 ontothe third section by rolling the bagged bale 1000 to a predeterminedlocation on the sealing module 800.

FIGS. 19-22 illustrate the sealing of the open end 910 of the bag 905using the sealing module 800. As illustrated in FIG. 19, once the baggedbale 1000 is positioned on the sealing module 800, the closing tool 825of the right and left closing actuators 805, 810 begin a sweep from acenter to the outside edges engaging the top flap of the open end 910.The right and left closing actuators, then reverse direction and sweepto move to the center of the sealing module 800 which engages right andleft flaps, respectively, of the open end 910.

The bottom actuator 815 then moves the closing tool 825 on the bottomactuator 815 upwardly towards the central position of the sealing module800 to move the bottom flap over the right, left, and top flaps to closethe open end 910. Once the bottom flap is nearly closed, the right andleft closing actuators 805, 810 are commanded to return the closing tool825 to their respective start positions.

A sealing element 830, e.g., a heat sealer, tape dispenser, or stapler,is then used to close the bottom flap. The sealing of the open end 910of the bag 905 can be sealed in a variety of ways and is not limited tothe foregoing description.

For example, as seen in FIG. 23, sealing module 800 is attached to theframe member of the bale bagging machine 100 (not shown for clarity) andcomprises transversely rotating side closure mechanisms 840 and rotatingtop closure mechanisms 850. In a similar manner as discussed above withrespect to the closure actuators 805, 810 of the sealing module 800, thetransversely rotating side closure mechanisms 840 are pivotably rotatedto move in a transverse direction with respect to the longitudinal feeddirection of the bale bagging machine 100 to engage the right and leftflaps of the open end 910 of the bag 905 and move the right and leftflaps towards the central position of the sealing module 800.

In this embodiment, top closure mechanisms 850 are then configured toengage the top flap of the open end 910 of the bag 905 by pivotallyrotating downwardly towards the central position of the sealing module800 to move the top flap towards the center of the sealing module 800.The bottom actuator 815 is then configured to move upwardly

towards the central position of the sealing module 800 to move thebottom flap over the right and left flaps. A sealing member, similar tothe devices discussed above, can then be used to close the flaps.

The disclosure is not to be limited by the description of exemplaryembodiments of the disclosure, but only by the scope of the appendedclaims.

For example, as seen in FIG. 1, a sampling station 1100 can be installedon the bale bagging machine 100. The sample station 1100 is coupled tovertical supports having one end coupled to the bottom frame member 105.The sample station 1100 comprises automated grippers 1105 mounted onends of an automated linear actuator 1110 with position indicationdevices.

The automated grippers 1105 are positioned to move transversely to thelongitudinal feed direction to allow the taking of a sample of the bale1000 from sides of the bale 1000. Once the bale 1000 is positioned atthe first position, the automated grippers are controlled by acontroller (not shown) to take the required samples.

The automated grippers 1105 can use fingers that open and close to grabthe sample or can use other devices that allow the taking of samplesfrom the bale. Once the sample is taken, the automated grippers 1105 arecontrolled to return to a position away from the bale 1000.

An automatic label applicator can also be installed on the bale baggingmachine 100 after the sealing module 800. The automatic label applicatorcan be installed as a separate station or coupled to the bottom framemember 105. The automatic label applicator is designed to place apreprinted label on the side of the bagged bale.

As the bale pusher 400 moves the bagged bale 1000 towards the sealingmodule 300, a switch is used to control the positioning of the automaticlabel applicator to engage the side of the bagged bale 1000 by movingtransversely towards the bagged bale 1000.

Additionally, the sealing module 800 can further comprise an automaticweighing station having load cells incorporated into the third section215. The automatic weighing station is designed to obtain a legal fortrade weight of every bagged bale 1000.

Specifically, driven rollers 216 are supported on the load cells (notshown) to weigh the bales. The driven rollers 216 are controlled using acontroller (not shown) to optimize the interface of the bagged bale withthe bag closing and sealing mechanisms, to ensure that the bagged baleis positioned correctly for weighing purposes, labeling, and datacollection or tagging verification purposes, and provide the control ofthe necessary speed and acceleration of the driven rollers to promotethe proper orientation of the bale.

A bale discharge roller conveyor 1200 can also be installed after thesealing module 800 or in place of the sealing module 800. The baledischarge roller conveyor 1200 can be coupled to the bottom frame member105 or separately attached to the sealing module 800.

The bale discharge roller conveyor 1200 has a base designed to supportbag closing, label application, bale weighing, and bale discharge fromthe machine. The bale discharge roller conveyor 1200 also has staticrollers and driven rollers to facilitate the discharge of the baggedbale 1000. An outfeed section of the bale discharge roller conveyor 1200has a set of gravity rollers that are isolated from the portion of theconveyor that is mounted to the load cells. These isolated rollersprevent excessive lateral forces from being exerted on the section ofthe conveyor mounted to the load cells. The bale discharge rollerconveyor is also equipped with a linear actuator for indexing ofmultiple discharged bales.

The bale discharge roller conveyor 1200 is engaged when the bale pusher400 advances to a predetermined position, so that the bagged bale 1000engages the driven rollers for the advancement of the bagged bale 1000.After the bag has been closed and sealed, the bagged bale 1000 isweighed. Once the bale has been weighed, the bale discharge rollerconveyor 1200 may begin discharging the bale 1000 by allowing the baleto reach the last roller and then fall on the floor.

As seen in FIG. 24, it is also contemplated that the embodiments of thebale bagging machine discussed above can further include a baletransferring system 1300 located at or near the bale feeding station300. The bale transferring system 1300 includes a bale transferringconveyor system 1310 having static rollers 1320, an overhead transferdevice 1330, and a support frame 1340. The support frame 1340 can besupported by vertical frame members 1350 and/or coupled to the balebagging apparatus 100. A transverse gantry beam 1360 is provided on thesupport frame 1340 so that the overhead transfer device 1330 can movetransversely with respect to the longitudinal feed direction of the balebagging apparatus.

In this embodiment, the bale bagging station 300 does not include sidebumper 311, instead, one end of the bale transferring system 1300 iscoupled to the bale feeding station 300 to feed a bale from an oppositeside of the bale feeding station 300 from the bale feeder 315. The otherend of the bale transferring system 1300 is coupled to adjacent baleprocessing equipment that is used to prepare the bales for subsequentbagging, for example, a bale pressing process. After completion of thepressing process, the bale 1000 is positioned on the static rollers 1320of the transferring conveyor system 1310 so that the overhead transferdevice 1330 is engageable with the bale 1000 to move and position thebale 100 transversely into the bale feeding station 300 to begin thebagging process.

Moreover, safeguards can be installed on the bale bagging machine 100for safety of the equipment and operators. For example, a safety switch(not shown) can be installed on the conveyor system 200 that detects anyobstruction to stop the bale pusher 800 from advancing in the directionof the longitudinal feed direction.

Additionally, while the methods of operation have been discussed abovein detail, the sequence of the steps is not limited to the abovedescribed method. In fact, the sequence of the steps can be performed inany order as needed for the bale bagging operation.

C. Discussion of Various Second Embodiments

In another embodiment, as shown in FIGS. 25A and 25B, a bale baggingmachine or apparatus 2000 includes a bale feeding station 2300 on afirst or front end 2301 of the bale bagging machine 2000. The baggingmachine further includes a sealing module 2800 on a second or back end2302 of the bagging apparatus 2000. According to an embodiment, thebagging apparatus 2000 further includes a bale chute 2500, a gantry2700, and a bale bagging station 2600 between the first and second ends2301 and 2302 of the bale bagging machine 2000.

As shown in FIGS. 25A and 25B, the bale bagging apparatus 2000, asdescribed herein, may be aligned along shown Cartesian coordinates withan x-axis, y-axis, and z-axis. As the bale is processed through the balebagging apparatus 2000 it may travel along the x-axis. The y-axisextends perpendicular to the x-axis and may lie in a plane parallel tothe floor on which the bale bagging apparatus 2000 is positioned. Thez-axis may extend perpendicular to the plane of the floor on which thebagging apparatus 2000 is placed, the z-axis also being perpendicular tothe x-axis and to the z-axis.

The bale bagging apparatus 2000 may have bottom frame members 2105 andvertical support members 2110. The bagging apparatus 2000 may also havetop support members 2120 extending horizontally from vertical supportmembers 2110 across the various processing stations or modules 2300,2600, and 2800. Panel portions, not shown, may then be attached to thevertical support members 2110 and top support members, to shield anoperator from the internal mechanisms of the bagging apparatus 2000.Access doors 2302 may be located at the front end of the bale baggingapparatus 2000 to provide access to the bale feeding station or othermechanisms located on the front end of the bale bagging apparatus 2000.Other various access portions may be provided on the outer cover of thebale bagging apparatus to provide access for an operator to the internalmechanisms of the bale bagging apparatus.

The bottom frame members 2105, vertical support members 2110, and topsupport members 2120 may have a solid or hollow beam and/or at least twolinear bars or beams to create a frame that has the linear bars or beamspositioned in parallel to the longitudinal feed direction and connectedtransversely by feet for supporting the base. The bottom frame member2105, vertical support members 2110, and top support members 2120 may bemade from steel, ferrous alloys, composite materials, or other materialthat can be used to support the stations and bale during the balebagging operation.

Additionally, the bottom frame members 2105, vertical support members2110, and top support members 2120 may support a top-mounted bale pusherassembly 2400. The bale pusher assembly is configured to push a bale tobe bagged along the x-axis direction of the auto bagger apparatus 2000,from the bale feeding station 300, through the bale bagging station2600, to the sealing module 2800. Although in the embodiment of FIGS.25A and 25B, and as shown in FIG. 30, the bale pusher assembly 2400 maybe a top-mounted bale pusher assembly 2400 with pusher head assembly2404 extending down, the top-mounted bale pusher assembly 2400 beingcoupled to top support members 2120, a bale pusher assembly may also bea bottom-mounted bale pusher assembly, coupled to a lower portion of thebale bagger apparatus with a pusher head assembly 2404 extendingupwards.

Alternatively, the bale pusher may be a side-mounted bale pusherassembly. Whether top-mounted, bottom-mounted, or side mounted, the balepusher assembly may include a pusher track assembly. A drive mechanismmay be configured to drive the pusher head assembly along the pushertrack assembly in the direction of the x-axis, to move a bale to bebagged and processed along the x-axis. Although the bale pusher assemblyis described herein as a means of moving the bale along the x-axis, thebale bagging apparatus is limited solely thereto, but may include othermeans of pushing, pulling, or otherwise moving a bale to be processedalong the x-axis of the auto bagger 2000.

The bale feeding station 2300 may include a bale receiver 2305 that isan opening that is used to receive a bale to be bagged 2001. The bale tobe bagged 2001 may be received from a direction parallel to they-direction, which is perpendicular to the feed direction (x-direction)of the auto-bagger. Alternatively, the bale to be bagged 2001 may bereceived from a direction parallel to the feed direction of theauto-bagger, or in other words, parallel to the x-direction. The bale tobe bagged 2001 may be received in a direction parallel to thex-direction or and aligned with the feed direction of the auto-bagger oroffset from the feed direction of the auto-bagger in the y-direction oreven the z-direction. The bale feeding station 2300 may alternativelyreceive the bale to be bagged 2001 from a direction having a componentin the z-direction, or be received from an input located above the balefeeding station 2300.

The bale feeding station 2300 may have transverse rotating rollers 2206coupled to a frame using pins or other fastening devices to allow therollers to rotate in a direction transverse to the feed direction(x-axis) of the auto bagger 2000. Alternatively, or even preferably,instead of rollers, the bale feeding station includes stationary railsalong which the bale to be bagged is slid. The exposed surface of therails may be covered with a low-friction material. Alternatively, thebale feeding station 2300 may simply be a planar surface with support tomaintain the bale to be bagged in an elevated position aligned with theother modules of the auto-bagger apparatus.

A staging device 2310 of the bale feeding station 2300 may include aside bumper 2311 located on the opposite side of the bale receiver 2305,to stop the movement of the bale to be bagged 2001 in the transversedirection (y-axis).

The staging device 2310 can also include a switch or a photoeye 2313 orlight curtain to detect the presence of the bale at the appropriatelocation. When the bale is detected by the switch or photoeye or lightcurtain 2313, the switch or photoeye or light curtain can be used tocontrol the movement of the drive unit 2312 roller device of the balefeeding station 2300.

As seen, for example, in FIGS. 25B and 30, the bale pusher 2400 may havea start position near the bale feeding station 2300. The bale pusher2400 has a pusher head assembly 2404, a pusher track assembly 2402, anda driving mechanism 2405 for moving the bale pusher head assembly 2404from the bale feeding section 2305 to the bagging station 2600 and backto the bale feeding section 2305. The pusher track assembly 2402 couplesthe pusher head assembly 2404 to the driving mechanism 2405 to allow thepushing of the bale in the longitudinal feed direction along the x-axis.

The pusher head assembly 2404 of the bale pusher 2400 may have a planarface 2414 that runs transversely to the longitudinal feed direction. Theplanar face 2414 may have a surface contact area 2415 that allows thedistribution of force on the pushed bale, so that the pushed bale is notdamaged. The pusher head assembly 2404 and pusher track assembly 2402may be made from steel, metal alloys, composites, and other materialthat is designed for moving loads.

The driving mechanism 2405 may move the bale pusher 400 along a lineardrive track 2402 coupled to the bottom frame member 2105 linearly in thelongitudinal feed direction. The driving mechanism 2405 can be driven bya servo gear motor 2416 that drives a rack (not shown), i.e., a gear,along a pinion (not shown) on the pusher track assembly 2402.Alternatively, other drive mechanisms may be used to move the drivingmechanism 2405 along the linear drive track 2402, such as, chains,pulleys, or similar devices.

Left sampling assembly 2352 and right sampling assembly 2351 may beprovided to a latter portion of the bale feeding station 2300. Before abag to be baled 2001 is pushed out of the bale feeding station 2300 andthrough bale chutes 2500, left and right samples or at least one,preferably at least two samples may be obtained by bale samplingapparatuses, such as left sampling assembly 2352 and right samplingassembly 2351. Such a sampling apparatus, may include the bale samplingapparatus as described by U.S. application Ser. No. 14/138,327,published as U.S. 2014/0174209, which is incorporated in its entirelyherein by reference.

The bale chute 2500 may be positioned at the front of the bale baggingstation 2600, between the bale feeding station and the bale baggingstation 2600. The bale chute 2500 has an input end 2505 near the balefeeding station 2300 and an output end 2510 near the bale baggingstation 2600 for receiving and discharging the bale moved longitudinallyalong the bale bagging machine 2000. The bale chute 2500 comprises atleast two pivoting sections, but preferably, has at least four pivotingsections 2515, 2516, 2517, 2518, mounted to the frame portion of theauto-bagger. For example, the bale chute may be coupled to chute frame2520 and attached to the bottom frame member 2105.

As seen in FIG. 36, the at least four pivoting sections 2515, 2516,2517, 2518 may be pivotally connected to the chute frame 2520 usingactuators 2525, e.g., double acting pneumatic cylinders, to move betweenat least a closed position and an open position. The positioning of theactuators 2525 are controlled using a controller (not shown).

FIG. 36 shows the at least four pivoting sections 2515, 2516, 2517, 2518pivoted in the open position. In a closed position, similar to otherembodiments described herein, the actuators 2525 pivot the pivotingsections 2515, 2516, 2517, 2518 towards each other to a center positionof the bale chute 2500, i.e., the pivoting sections are pivoted towardsthe other pivoting sections. In the open position, the at least fourpivoting sections 2515, 2516, 2517, 2518 are pivoted from the closedposition to the open position, where the four pivoting sections 2515,2516, 2517, 2518 are driven outwardly away from the center position ofthe bale chute 2500, i.e., the pivoting sections are pivoted away fromthe other pivoting sections.

The bagging station 2600 is located after the bale feeding station 2300and the bale chute 2500. The bagging station 2600 according to anembodiment, instead of having a roller section, as described in otherembodiments, may include a simplified bag/bale apparatus. In oneembodiment, the bag/bale apparatus includes bag/bale gate 2601, whichmay include slides including rails 2620 and 2621 with a slide surface2610 and 2611 formed on each respective rail 2620 and 2621. The railsmay be formed of formed steel, angle iron, ferrous alloys, compositematerials, or other material that can be used to support the stationsand bale during the bale bagging operation. Slide surfaces 2610 and 2611may be formed from a material that facilitates a sliding of the balebeing processed (i.e., a material having a low coefficient of friction),as the bale is pushed along the top of the slide surfaces 2610 and 2611.The slide surfaces may be made from a Teflon based material, UHMW (UltraHigh Molecular Weight Polyethylene), or PTFE Sheet(PolyTetraFlouroEthylene). A bag receptacle 2651, which may include adrawer mechanism 2650 openable by traveling in a direction parallel tothe y-axis by an operator pulling on handles 2655, may be placed withinthe bagging station 2600 below the bag/bale gate 2601 and below thepusher track assembly 2402. At ends 2622, 2623, 2624, and 2427, of therails 2620, 2621, rollers of linear bearings may be provided to allowtravel of the rails 2620, 2621, along support members 2615, 2616, in adirection parallel to the y-axis, as represented by the large arrows.

Alternatively, rails 2620 and 2621 may be provided, according to oneembodiment, the rails are stationary with respect to the support members2615, 2616, are positioned at such a position as to provide a sufficientgape or opening 2660 through which a bag to be used in the bagging ofthe bale may be retrieved, while still providing sufficient verticalsupport for the bale to be bagged.

According to an embodiment, when the gantry 2700 is to obtain a bag tobe placed around the bag to be baled 2001, rails 2620, 2621 of bag/balegate 2601 may be pushed by actuator 2625 to a position toward the outeredge of the bagging station 2600, to provide space through which toretrieve the bag through gap or opening 2660. Then, after the bag isretrieved, the rails 2620, 2621 may be pushed backed toward a centerline of the bag bail gate to allow the bale to be bagged to slide acrossthe top surfaces of the side surfaces 2610, 2611.

Additionally, as shown in the arched arrows of FIG. 37, depending on thesize or geometry of the bag to be placed over the bale to be bagged,rails 2620, 2621 may be pivoted around pivot points, for example, asshown at points 2631 and 2632, when pushed to the outer position, toprovide even more room or a larger opening 2660 through which toretrieve the bag. For example in the case that larger bag is to be usedto bag the bale, for example, in the case that a non-gusseted bag isused, the non-gusseted bag has a larger cross section area, when viewedin the top-plan view, and thus a larger opening 2660 is preferable.Additionally, to provide control of the bale being processed, rails maybe formed to provide a slide surfaces angled in at an angle β with ahorizontal plane. Such an arranged bale bagging station 2600 may bepreferable to bagging stations of other embodiments described herein, asthe bale bagging station 2600 does not include rollers which may pinchor remove the bag or a portion of the bag from the bale, or otherwisestall the transport of the bale. Additionally, providing the bagreceptacle 2602 within the lower portion of the bale bagging station asopposed to the side of the bale bagging station, permits the balebagging station 2600 to be self-contained and covered and thus lessexposed and susceptible to damage or harm to operators.

As shown in FIGS. 30 and 33, gantry assembly 2700 may travel along aportion of the pusher track assembly 2402 in a direction parallel to thefeed direction of the auto bagger, parallel to the x-axis. Gantryassembly 2700 includes left and right gantry arms 2705, 2704, configuredto be driven in the z-direction by drive mechanisms 2703 and 2702,respectively. Bag retrieving units 2730, 2731, are provided on a lowerportion of gantry assembly 2700, coupled to a lower end of gantry arms2703 and 2704. Bag retrieving units 2730, 2731 may have suction cups2710 configured to grasp a bag to be retrieved from bag receptacle 2650.Other bag grasping mechanisms may be used beside suction cups, such asclamps, gripping fingers, that are configured to grasp the baling bagsfor displacing the bags, i.e., pick up, from a bag receptacle providedbelow the bag/bale gate. The movement of the gantry 2700 in the x-axismay be provided by gantry trolly 2725.

According to an embodiment, servo motors, gear or chain drivers, orvarious structures or assemblies may be used by gantry trolly and withinthe gantry assembly to provide movement of the gantry 2700 in thex-direction and movement of the gantry arms 2705, 2704 in thez-direction, to allow the gantry to receive a bag from the bagreceptacle positioned below the bag/bale gate, move the bag forward tobe placed around the chutes, and provide support to the open end of thebag while the bale is pushed through the chutes and into the open end ofthe bag.

Upon being placed inside the bag, the bag is pushed through the balebagging station 2600 by the bale pushing apparatus, and into the sealingmodule 2800, wherein the open end of the bag, which faces the front ofthe bagging apparatus, is closed and fastened closed.

The sealing module 2800 is a sealing used to tape or a heating element2830 to close the open end of the bag around a bagged bale. Staples,pins, or other fastening mechanism may also be used to fasten the openend of the bag closed once properly folded closed within the sealingmodule.

The sealing module 2800, may include closure assembly 2801, which asshown in FIG. 41, may include a left side closure 2810 and a right sideclosure 2811, which are made to pivot at pivot units 2813 and 2812,respectively, when pushed by actuators (not shown) to sweep the sideclosures 2810, 2811, to make contact with the open end of the bag, andpush the side flaps together.

Sweeping side closures or the pivoting two stage side closures may beutilized to close the open end of the bag. In the two-stage sideclosures, the first stage may be a pivoting action swinging the sideclosures in to make contact with the open bag, and the second stagebeing an extension of the side closures pushing the flaps to together.

The angled edges 2825 2826 of side closures 2810, 2811, provide a usefuledge shape to bring the side flaps of the bag together. When the sideflaps of the open end of the bag are brought together, the bottomportion of the bag may then be formed over the folded side flaps, whenpushed by actuator 2817. Upon folding the bottom flap over the foldedside flaps, the top folding unit 2816, pushed by actuator 2818, may pushthe last flap, the top flap over the bottom and side flaps. The top flapmay be fastened closed in various ways, although a heat element 2830 maybe preferable, to heat seal the top flap closed.

Although in this embodiment, the bottom flap is described as beingfolded before folding and sealing the top flap, the order of the topflap and bottom flap may be reversed, with the top flap being foldedfirst and the bottom flap being folded and then sealed or fastened tothe top flap. Similarly, the bottom and top flaps may be folded ineither order (top then bottom or bottom then top), then either the leftor right side flap can be folded over the bottom and top flaps, and theother of the left or right side flap can be folded over and heat-sealedor otherwise fastened to the other folded flaps.

Upon fastening the open end of the bag closed by the closure assembly,the bagged bale can be weighed within the sealing module 2800 on weighttable assembly 2850, as shown in FIG. 43. The weight table assembly mayinclude a support structure that supports the bagged bale and mayinclude a scale to weigh the scale. In one embodiment that is not shown,rails may be provided that extend in the x-direction, which allow thebagged bale 2002 to be slid across the weight table assembly. In anotherembodiment, may include a non-slip belt 2860, driven by belt drive unit2865 around rollers 2861 and 2862. Other final processing steps, such aslabelling, printing, and label scanning may also be performed to thebagged bale, while it is located within the sealing module 2800.

As shown in FIG. 44, when all processing of the bagged bale 2002 isperformed, bagged bale 2002 may be moved along the x-direction bymovement of non-slip belt 2860 until the bale makes contact with feet2876, 2877 of bale drop unit 2875. Actuator 2879 may drive a pivotmotion, as shown by the arced arrow below the bale drop unit 2875,pivoting around pivot point 2879.

As shown in FIG. 45, according to one embodiment, when the bagged baleis dropped or pivoted to the floor, a bale push unit 2895 may beprovided, which includes cylinder 2890 that pushes push head 2891. Thepush head 2891 pushes the bagged bale in a direction parallel with thex-axis, to remove the upright or otherwise placed bagged bale from thefeet 2876, 2877 of the bale drop unit 2875. Bagged, weighed, labelled,scanned, and fully processed bale 2002 may then be moved to anotherlocation.

Although the above embodiments describe a bale bagging apparatusconfigured to bale a cotton bale, the disclosure is not limited tobagging a cotton bale, but can be equally applied to bagging a bale ofany fibrous material, for example a bale of agricultural products, suchas, but not limited to, wool, cotton, hemp, flax, etc., or other fibrousmaterials, either naturally or synthetically produced.

Additionally, while the methods of operation have been discussed abovein detail, the sequence of the steps is not limited to the abovedescribed method. In fact, the sequence of the steps can be performed inany order as needed for the bale bagging operation.

1. A bale bagging apparatus comprising: a bale feeding station; a balechute; a bale bagging station; and a transportation system configured totransport a bale to be bagged from the bale feeding station through thebale chute and into the bale bagging station, wherein the bale baggingstation includes a bag receptacle, a first opening, and a bag retrievalassembly, the first opening being defined by a first rail and a secondrail, the bag receptacle being positioned on a side opposite of thefirst opening from the side of the first opening on which the bale to bebagged is to be transported, the bag retrieval assembly being configuredto retrieve a bag from the bag receptacle through the first opening, andwherein the bag retrieval assembly is configured to position a first endof said bag around at least a portion of the bale chute before the baleto be bagged is transported through the bale chute by the transportationsystem.
 2. The bale bagging apparatus according to claim 1, wherein thebag receptacle is positioned below the first opening, and wherein thefirst opening is provided between the first rail and the second rail,and the first rail and the second rail are support rails configured tosupport the bale to be bagged when the bale to be bagged is transportedpast the opening.
 3. The bale bagging apparatus according to claim 1,wherein the transportation system includes a bale pusher configured topush the bale to be bagged along an axis of the bale bagging apparatus.4. The bale bagging apparatus according to claim 1, wherein the bagreceptacle is positioned below the first opening, the first rail and thesecond.
 5. The bale bagging apparatus according to claim 1, wherein thefirst rail and the second rail each have a surface material provided onthe surface configured to contact the bale to be bagged, the surfacematerial being a low-friction material.
 6. The bale bagging apparatusaccording to claim 1, wherein the bale bagging station includes abale-bag gate comprising the first rail and the second rail, thebale-bag gate being configured to increase the width of the firstopening in a direction perpendicular to the direction in which the baleto be bagged is transported to allow retrieval of the bag through thefirst opening.
 7. The bale bagging apparatus according to claim 6,wherein the bale-bag gate is configured to support the bale to be baggedwhen the bale to be bagged is transported over the bale-bag gate.
 8. Thebale bagging apparatus according to claim 7, wherein a top surface ofeach of the first rail and the second rail are inclined at an angle βsuch that for each of the first rail and the second rail, a portion ofthe top surface arranged toward a center of the bale bagging station islower in height than a portion of the top surface arranged further awayfrom the center of the bale bagging station, the top surface of each ofthe first rail and the second rail being configured to contact the baleto be bagged as the bale to be bagged is transported through the balebagging station.
 9. The bale bagging apparatus according to claim 1,wherein the bag retrieval assembly includes a gantry, the gantry beingconfigured to move in a first direction as the bag is retrieved from thebag receptacle, and the gantry is configured to move in a seconddirection to place the open end of the bag around the bale chute, thefirst direction being different from the second direction.
 10. The balebagging apparatus according to claim 1, further comprising a sealingmodule configured to close the first end of said bag after the bale tobe bagged has been placed into said bag.
 11. The bale bagging apparatusaccording to claim 3, wherein the bale pusher is a top-mounted balepusher assembly configured to push the bale to be bagged along the axisof the bale bagging apparatus.
 12. The bale bagging apparatus accordingto claim 3, wherein the bale pusher is a bottom-mounted bale pusherassembly configured to push the bale to be bagged along the axis of thebale bagging apparatus.
 13. The bale bagging apparatus according toclaim 1, further comprising panel portions covering an outer surface ofthe bale bagging station.
 14. The bale bagging apparatus according toclaim 6, wherein the first rail and the second rail of the bale-bag gateare each configured to pivot about a respective pivot axis, each of therespective pivot axes being arranged at least parallel to the directionin which the bale to be bagged is transported through the bale baggingapparatus, the pivoting of each of the first rail and the second railincreasing the width of the first opening.
 15. The bale baggingapparatus according to claim 1, wherein the bag receptacle is a drawercontainer configured to store bags to be used by the bale baggingapparatus.
 16. The bale bagging apparatus according to claim 1, whereinthe bale bagging station further includes a bale sampling unitconfigured to retrieve at least one sample from the bale to be bagged.17. The bale bagging apparatus according to claim 1, further comprisinga weigh table assembly configured to weigh the bale to be bagged. 18.The bale bagging apparatus according to claim 1, further comprising abale drop unit configured to lower the bale to be bagged from a firstposition to a second position by tiling the bale to be bagged after thebale to be bagged is transported from the bale bagging station.
 19. Thebale bagging apparatus according to claim 10, wherein the sealing moduleis arranged along an axis of the bale bagging apparatus such that thebale bagging station is arranged between the bale feeding station andthe sealing module, and wherein the sealing module includes at least afirst closure arm and a second closure arm, the first closure armconfigured to fold a first portion of the first end of the bag towards acenter of the bale to be bagged and the second closure arm folding asecond portion of the first end of the bag towards the center of thebale to be bagged.
 20. A method of bagging a bale, the methodcomprising: receiving a bale to be bagged at a feeding station;retrieving a bag from a bag receptacle through a first opening, thefirst opening being defined by a first rail and a second rail, the bagreceptacle being positioned on a side opposite of the first opening fromthe side of the first opening on which the bale to be bagged is to betransported; positioning a first end of said bag around at least aportion of said chute; and transporting said bale to be bagged throughsaid bale chute and thereby placing said bale to be bagged within saidbag.